Cake box

ABSTRACT

A cake packaging employs special locks that allow bakers and bakery customers to open and close the packaging without risk of damaging the cake inside, but the elements work together so the fully-erected structure hides the less-than-sleek geometry of the locking mechanisms even as these obscuring panels are tucked into one another to secure the panels and give the packaging strength.

BACKGROUND OF THE INVENTION

The present invention relates to bakery items, and more particularly cake boxes.

Bakers need cake packaging that will allow them to slide a cake into the structure and secure the structure without having to reach inside the packaging where fragile design elements of the cake could be damaged from fingers and hands trying to finish assembly of the packaging. Once a cake is delivered, the design of the packaging should also allow a bakery customer to open and slide out the cake without having to reach inside of the structure where the cake itself could be damaged.

Other solutions may also require bakers and bakery customers to go through non-intuitive steps to construct and open the cake packaging that are time-consuming and frustrating.

Other cake packaging in the art have positive locking mechanisms to secure the structure around the cake. However, the ability to release these positive locks for cake removal requires reaching into the packaging where the frosting of the cake may be bumped and damaged. Other solutions trying to solve this problem consist of two or more elements (e.g., a base and a lid). However, multiple parts to a package raise the cost of the packaging when compared to a single-piece solution. This design not only employs special locks that allow bakers and bakery customers to open and close the packaging without risk of damaging the cake inside, but the elements work together so the fully-erected structure hides the less-than-sleek geometry of the locking mechanisms even as these obscuring panels are tucked into one another to secure the panels and give the packaging strength.

As can be seen, there is a need for an apparatus and method for forming a cake box to prevent damage to the cake or decorative embellishments.

SUMMARY OF THE INVENTION

In one aspect of the present invention a unitary sheet of material is formable into a box structure. The unitary sheet includes a bottom panel with a right side panel, a left side panel, a front panel and a rear panel, that extend laterally outward from the bottom panel. A closure flap extends laterally outwardly from a right and a left side of each of the front panel and the back panel. An arcuate slot is defined laterally across a mid portion of the right side panel and the left side panel. A securement tab is defined at each of a lower end and an upper end of the closure flap, distal to the respective front panel and rear panel. A closure notch is defined in the right side panel and the left side panel along a top margin of the right side panel and the left side panel, wherein a lower securement tab is configured to be received within the arcuate slot and an upper securement tab is configured to be received in the closure notch to join the front panel and the rear panel to the right side panel and the left side panel.

In some embodiments, a top panel extends from the rear panel along an edge opposite the bottom panel. A tuck flap may extend outwardly for the lateral sides of the top panel, wherein the tuck flap is configured to be received within the arcuate slot during closure of the top panel. In other embodiments, a top latch extends from an edge of the top panel opposite the edge connecting the top panel to the bottom panel. A latch tab may protrude from a distal edge of the top latch. In yet other embodiments, a latch notch defined along an upper margin of the front panel, wherein the latch notch is dimensioned to receive the latch tab.

A score line may be defined along a boundary between the bottom panel and one or more of the right side panel, the left side panel, the front panel, the rear panel. Similarly, a score line defined along a boundary between the side panel and the closure flap. A score line may also be defined along a boundary between the top panel and one or more of the tuck flap and the top latch.

In a preferred embodiment, a spacing between a base of the upper securement tab and a base of the lower securement tab is at least a spacing between the arcuate slot and a top edge of the closure notch.

These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, description and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of the cake box, shown laid flat;

FIG. 2 is a perspective view of the cake box, illustrating the raising of the side panels, with a cake 74 shown in hidden lines for clarity;

FIG. 3 is a perspective view of the cake box, illustrating the raising of the front and back panels and the connection of the front panel to the side panels;

FIG. 4 is a perspective view of the cake box, illustrating the lowering of the top panel and the connection of the top flaps to the side panels;

FIG. 5 is a perspective view of the cake box, illustrating the final connection of the top panel; and

FIG. 6 is a perspective view of the cake box, illustrating the opening of the box for cake removal or insertion.

DETAILED DESCRIPTION OF THE INVENTION

The following detailed description is of the best currently contemplated modes of carrying out exemplary embodiments of the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.

Broadly, embodiments of the present invention provide a cake packaging that allows bakers to assemble the carton structure around the cake without risk of damaging the contents by having to reach inside. This will also allow bakery customers to open the packaging without having to reach inside of the structure to remove their cake from the packaging.

Any packaging element that causes a baker or a bakery customer to have to fuss with the structure formed around the cake increases the odds that the cake or its decorative element will be bumped and damaged. Other cake box solutions do not have a locking mechanism that is this easy to engage and disengage while maintaining the structural integrity of a fully erected cake package. Bakery customers want products that are visually appealing. Complicated packaging that attempts to solve the problem of easy to assemble and disassemble design elements detract from the beauty of the presentation to the customer.

The cake box of the present invention not only employs special locks that allow bakers and bakery customers to open and close the packaging without risk of damaging the cake inside, but the elements work together so the fully-erected structure hides the less-than-sleek geometry of the locking mechanisms even as these obscuring panels are tucked into one another to secure the panels and give the packaging strength.

Features of the cake box 10 according to the present invention will be described in conjunction with assembly of the box 10. As seen in reference to FIG. 1, the cake box 10 is formed from a flat die-cut material. The cake box includes a bottom panel 12, a right side panel 14 and a left side panel 22, a front panel 30, a rear panel 48, a top panel 62, and a top latch 68. The right 14 and left side panels 22 extend laterally outward from opposite sides of the bottom panel 12. The front 30 and rear panel 48 extend outwardly from the remaining opposed sides of the bottom panel 12. A score line is defined between the bottom panel 12 and its connections with the right 14, left 22, front 30, and rear 48 panels to facilitate folding of the panels to form the box 10.

Throughout assembly the box 10, the bottom panel 12 remains against a supporting flat surface. As seen in reference to FIG. 2, a cake 74 may be positioned on the bottom panel 12 before assembly of the cake box 10 around the cake 74. The right 14 and left 22 side panels are folded along their score lines to position the side panels substantially perpendicular to the bottom panel 12. As seen in reference to FIG. 3, the front panel 30 and the rear panel 48 may then be folded about their respective score lines to position the front 30 and rear 48 panels in a vertical orientation about the cake 78.

The front panel 30 has a right 36 and a left 42 closure flap that extend laterally outwardly from the right and left sides of the front panel 30. Each closure flap 36, 42 having securement tabs defined at an upper 38, 44 and a lower 40, 46 end of the flaps 36, 42. Likewise, the rear panel 48 has a right 50 and a left 56 closure flap that extend laterally outwardly from the right and left sides of the rear panel 48. Each rear closure flap 50, 56 has securement tabs 54, 50 defined at a lower end thereof an securement tabs 58, 52 defined at the upper ends of the closure flaps 50, 56. A score line is defined along the boundary between each of the respective front 30 and rear back panel 48 and their corresponding closure flap 36, 42, 50, 56. The closure flaps 36, 42, 50, 56 are folded along the score line to conform to the right 14 and the left 22 side panels.

The lower securement tabs 40, 46, 54, 60 are disposed for cooperative engagement with an arcuate slot 20, 28 laterally defined across a mid portion of the respective side flaps 14, 22. The upper securement tabs 38, 44, 52, 58 are disposed for cooperative engagement with a closure notch 16, 18, 24, 26 defined along a top margin of the respective right 14 and left 22 side panels. The closure notches 16, 18, 24, 26 may be formed by an inverted U shape cut line. The upper securement tabs 38, 44, 52, 58 may be conveniently secured within the closure notch 16, 18, 24, 26 simply by pressing an upper portion of the tab 38, 44, 52, 58 so that the tab 38, 44, 52, 58 protrudes into the corresponding closure notch 16, 18, 24, 26.

Alternatively, the structural material of the closure flaps 36, 42, 50, 56 may be temporarily warped out from the structure allowing the upper lock tab 38, 44, 52, 58 to be inserted into the closure notch 16, 18, 24, 26. The upper lock tab 38, 44, 52, 58 extends beyond the top of the top closure notch 16, 18, 24, 26. When the warped material between the upper lock tab 38, 44, 52, 58 and the lower tab 40, 46, 54, 60 is relaxed, the overall distance from the top of the base of the upper tabs 38, 44, 52, 58 and base of the lower tab 40, 46, 54, 60 is preferably greater than the distance between the top of the closure notch 16, 18, 24, 26 and the arcuate slot 20, 28 of the side panels 14, 22 so as to bias the upper tabs 38, 44, 52, 58 and the lower tabs 40, 46, 54, 60 to prevent the tabs from falling or sliding out of their slots, allowing the box 10 to retain its shape.

As seen in reference to FIG. 3, the top panel 62 has a right 64 and a left 66 tuck flaps extending outwardly from the lateral sides of the top panel 62. A score line is defined between the tuck flaps 64, 66 and the top panel 62. The tuck flaps 64, 66 are folded along the score lines. As seen in reference to FIG. 4, a distal end of the tuck flaps 64, 66 is received within the corresponding arcuate slot 20, 28 such that the tuck flaps 64, 66 overlie the adjacent ends of the closure flaps 36, 42, 50, 56.

The top latch 68 has a score line defined between it and the top panel 62. The top latch 68 has one or more latch tabs 70, 72 protruding from a distal end of the top latch 68. The front panel 30 has a corresponding one or more latch notches 32, 34 to cooperatively engage with the one or more latch tabs 70, 72.

The top panel 62 lid is folded at ninety degrees on the score line so it is resting on the upper edge of the side panels 14, 22 and the front and rear panels 30, 48. The tuck flaps 64, 66 are folded down ninety degrees along the their score lines, putting it parallel to the side panels 14, 22. The top flap 62 is opened slightly in order to allow the distal ends of the tuck flaps to line up the arcuate slots 20, 28. With the lower securement tabs 40, 46, 54, 60 received in the arcuate slots 20, 28, the material beneath the arcuate slots 20, 28 is offset from the material above the arcuate slot 20, 28 by the thickness of the material so that the arcuate slots 20, 28 are partially opened to receive the distal ends of the tuck flaps 64, 66. While the top panel 62 is coming down to close the top of the package the tuck flaps 64, 66 are received inside of the arcuate slots 20, 28.

To open the package to remove contents, the top panel 62 can be opened allowing the tuck flaps 64, 66 to be pulled out from the arcuate slots 20, 28 to expose the closure flaps 36, 42, 50, 56. To disengage the cooperating upper 38, 44, 52, 58 and lower tabs 40, 46, 54, 60 from their corresponding notches 16, 18, 24, 26 and arcuate slots 20, 28, a user only needs to use a fingertip to grab the edge of the closure flaps 36, 42, 50, 56. Pulling the material out at that spot with just one finger will warp the material so the distance between the top of the upper lock tabs 38, 44, 52, 58 and bottom of the lower lock tabs 40, 46, 54, 60 becomes shorter than the distance between the top of the closure notches and the arcuate slot 20, 28, allowing the tabs to be released from the side panel 14, 22.

How to Make the Invention:

This packaging 10 would be cut from a flat piece of material that is machined from a roll or a sheet. This could be done with a die, a laser, or any method that could cut and score or cut and perforate the necessary geometry.

In use, the bakery personnel would set up half of the structure leaving one side open with a selected panel laying flat on the table. The cake 74 would be slid onto the flat side panel and into the structure by applying pressure to the outside edge of the cake board. Once the cake 74 was inside, the baker would fold up the side panel and bring around the lock tab panels and secure them into the side panel all while keeping their fingers from reaching inside of the packaging and away from the frosting of the cake. They would close the top panel 68, tucking the tuck flaps 64, 66 into the arcuate slot 20, 28 to finish the structure.

When the cake 74 needs to be removed, the top panel 68 would be opened allowing the tuck flaps 64, 66 to move up and away from concealing the 38, 44, 52, 58 and bottom of the lower lock tabs 40, 46, 54, 60 and their corresponding slots 16, 18, 24, 26 and with a fingertip pulling at the center of the closure flaps 36, 42, 48, 50. The edge of the cake board could then be pulled out of the packaging 10 or the locks on the other side of the structure could be disengaged and the cake 74 could be pushed from one side out of the other—all without having to reach inside of the packaging near the cake 74.

The specialty locks of this design could be used in any situation where there was no access or difficult access on the other side of the panel containing the locking slots. The overall design could also be used for packaging anything where it is not desirable to have to reach inside of the structure.

It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims. 

1. A unitary sheet material formable into a box structure, comprising: a bottom panel with a right side panel, a left side panel, a front panel and a rear panel, that extend laterally outward from the bottom panel; a closure flap that extends laterally outwardly from a right and a left side of each of the front panel and the back panel; an arcuate slot defined laterally across a mid portion of the right side panel and the left side panel; a securement tab defined at each of a lower end and an upper end of the closure flap, protruding in an upward and a downward direction, respectively, at an end of the closure flap distal to the respective front panel and rear panel; and a closure notch defined in the right side panel and the left side panel along a top margin of the right side panel and the left side panel, wherein a lower securement tab is configured to be received within the arcuate slot and an upper securement tab is received in the closure notch to join at least one of the front panel or the rear panel to at least one of the right side panel or the left side panel.
 2. The unitary sheet material of claim 1, further comprising: a top panel extending from the rear panel along an edge opposite the bottom panel.
 3. The unitary sheet material of claim 2, further comprising: a tuck flap extending outwardly for the lateral sides of the top panel, wherein the tuck flap is configured to be received within the arcuate slot during closure of the top panel.
 4. The unitary sheet material of claim 3, further comprising: a top latch extending from an edge of the top panel opposite the edge connecting the top panel to the bottom panel.
 5. The unitary sheet material of claim 4, further comprising: a latch tab protruding from a distal edge of the top latch.
 6. The unitary sheet material of claim 5, further comprising: a latch notch defined along an upper margin of the front panel, wherein the latch notch is dimensioned to receive the latch tab.
 7. The unitary sheet material of claim 1, further comprising: a score line defined along a boundary between the bottom panel and one or more of the right side panel, the left side panel, the front panel, the rear panel.
 8. The unitary sheet material of claim 1, further comprising: a score line defined along a boundary between the side panel and the closure flap.
 9. The unitary sheet material of claim 4, further comprising: a score line defined along a boundary between the top panel and one or more of the tuck flap and the top latch.
 10. The unitary sheet material of claim 1, wherein a spacing between a base of the upper securement tab and a base of the lower securement tab is at least a spacing between the arcuate slot and a top edge of the closure notch. 